100% Employee Owned, Founded 1954

FCI Case Study: Thermal Flow Meters for Hydrogen at Power Plants

Supplier Resource

FCI Case Study: Thermal Flow Meters for Hydrogen at Power Plants 1

Thermal Flow Meters Help Electric Power Plants Keep Their Cool with Hydrogen Gas

FCI Case Study: Thermal Flow Meters for Hydrogen at Power Plants 2This case study from FCI discusses the challenges faced in electric power generation plants, particularly in managing the heat generated during the process of electricity generation. In these plants, a fuel source heats a boiler, creating steam that drives turbines, ultimately generating electricity. The critical issue is managing the heat produced during this process, particularly in the wire coils of generators, which need to be continuously cooled to prevent overheating, degradation, and failure.

Hydrogen (H2) is the most efficient coolant for generators, but it comes with safety concerns due to its small molecule size, combustibility, and potential for leaks. The U.S. Department of Occupational Safety and Health Administration (OSHA) highlights the risks associated with hydrogen, including its tendency to concentrate in overhead areas and ignite easily.

To address these challenges, the case study discusses two specific problems and solutions:

Problem 1: Difficulty accurately measuring hydrogen leakage from storage cylinders to a generator. Solution 1 involved the installation of an FCI ST75V Series Thermal Mass Flow Meter, which accurately measures gas mass flow without requiring separate temperature and pressure transmitters. This meter improves accuracy, reliability, and safety in monitoring hydrogen leakage rates.

Problem 2: Ensuring the generator is filled with a sufficient amount of hydrogen after purging with CO2. Solution 2 involved installing a second ST75V Series flow meter to measure the hydrogen refill rate and totalized flow volume from cylinders back into the generator, ensuring proper cooling of the electrical coil.

Both flow meters are designed to connect with industry-standard communication protocols, providing data for programmable logic controllers (PLCs) and distributed control systems. They are rugged, maintenance-free instruments with built-in temperature compensation and direct mass flow measurement capabilities. The installation of thermal flow meters has improved the safety and efficiency of the electric power generation plant by accurately monitoring hydrogen leakage rates and ensuring adequate cooling of generators. These meters have been successfully installed and commissioned, providing consistent and reliable data for plant operations.

As an exclusive representative for Fluid Components International, Cross offers the complete line of FCI flow equipment throughout our territories in the mid-Atlantic area, including; Maryland, Virginia, and Washington D.C. Take a look at the full case study from FCI and contact a Cross process solutions expert to discuss how FCI products can increase efficiency in your operation.

See How A Solution From Fluid Components International Can Benefit Your Operation

Latest Cross Company Updates

CMS Cepcor, a leading supplier of aftermarket crusher spares and equipment to global industries, enhanced its quality control with the acquisition of an Altera M coordinate measuring machine.
April 29, 2025
parker transair in action
Parker’s Transair system is an industry leader when it comes to efficient, reliable, and clean piping for compressed air and industrial transfer applications.
April 29, 2025
Our own Jim Hewson, quality director for the Cross Precision Measurement group joins Chuck & Howie from the NAPT Podcast.
April 28, 2025
Cross Logo
Omron Logo
Flow Waterjet, a leader in industrial shape cutting, sought to enhance their machines to meet rising demands for precision and flexibility. Partnering with OMRON Automation, they integrated advanced motion control and safety systems, resulting in machines with unprecedented precision and efficiency.
April 25, 2025
Cross Logo
Brooks Instrument Case study: Using BEST Software to Prevent Process Failures
April 15, 2025

Contact our Team

Hang Tight! We're Searching... Searching... Searching...

We’re looking through thousands of pages to find the most relevant information.

In the meantime, enjoy these fun facts…

Did you know… Cross Company is an ESOP (Employee Stock Ownership Plan). Our ESOP started in 1979 and as of 2006, we are 100% employee-owned! Learn more about our ESOP and how that benefits both team members and our customers.
Did you know... the precision measurement group at Cross was founded in 1939 by our current CEO's grandfather, Jim King. That's a whole lot of calibration!
Did you know... A fingerprint weighs about 50 micrograms. We know, we weighed it! The residue left from a finger can actually make a difference in weight results which is why we wear gloves when we calibrate weights. For reference, a sheet of paper is about 4.5 grams, that’s 4.5 million micrograms.
Did you know… Cross Company has grown significantly since our start in 1954. Over the years we've acquired 26 companies! Today, our five groups have expertise in everything from industrial automation to precision measurement, and industry knowledge going all the way back to 1939.